Four sided pillow packaging for granola product

ABSTRACT

A package can be used to provide a food product to a consumer. The packaging can include a four sided pillow package, wherein the package can include a laminate including at least one plastic layer and a layer of rice paper. A four sided ultrasonic seal can also be designed into the packaging to render it water proof, a machine creating the four sided ultrasonic seal utilizing a variety of films of varying composition or thickness.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority of U.S. Provisional Patent Application No. 61/827,032 filed May 24, 2013, the contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

This disclosure is related to packaging utilized in a retail product, such as including but not limited to a loose fill granola product or other solid, semi-solid, viscous or liquid product. The packaging in particular includes a multi-sided pillow package construction, such as which can include any dual plastic ply which can be secured or ultrasonically welded in any desired fashion and which can be of a hands free or free standing construction.

BACKGROUND OF THE INVENTION

The statements in this section merely provide background information related to the present disclosure. Accordingly, such statements are not intended to constitute an admission of prior art.

Granola is a cereal product including grains and other ingredients. Granola frequently includes rolled oats, honey, nuts, and ingredients providing a desired flavor. Granola products are frequently pressed into a bar shape.

Food products can be individually packed for consumption by consumers. Snack products like granola bars and candy bars can be wrapped in a foil or plastic wrapper. A known method to create such a wrapper includes utilizing a single piece of material, wrapping the material around the product, aligning the wrapper so that a printed label defines a front side of the product, and sealing the two sides of the wrapper along a back side of the product. The seal along the back side of the product results in a flap running down the length of the back side of the product. The wrapper is additionally sealed at each end of the bar product. The resulting packaging provides a product with a front side that can include images and logos that can be used to market and decorate the product, making the product more appealing to the consumers. However, the back side of the product including the wrapper seal running the length of the product is less presentable. Manufacturers frequently use this back side of the product as undesirable space on the packaging, listing information required by regulation, printing expiration date information, bar codes, and other similar perfunctory information. The consumer, making a decision whether or not to purchase the product, is presented with one front side of marketable decorative print, whereas the back side of the product cannot include a full side of marketable decorative print. A manufacturer must choose whether to fit small amounts of decorative print around the wrapper seal or simply to write off the opportunity to market to the consumer on the back of the product.

SUMMARY OF THE INVENTION

A package can be used to provide a food product to a consumer. The packaging can include a four sided pillow package, wherein the package can include a laminate including at least one plastic layer and a layer of rice paper. Other features include a four sided ultrasonic seal which can also be designed into the packaging to render it water proof, with an associated ultrasonic film machine creating the four sided ultrasonic seal utilizing a variety of films of varying composition or thickness.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 illustrates a front side of an exemplary four sided pillow package for use in providing a food product to the consuming public, in accordance with the present disclosure;

FIG. 2 illustrates a back side of the four sided pillow package of FIG. 1, in accordance with the present disclosure;

FIG. 3 illustrates a front side of an exemplary four sided pillow package, wherein a top of the package has been removed across a tear line defined by two tear features, in accordance with the present disclosure;

FIG. 4 illustrates a back side of the four sided pillow package of FIG. 3, in accordance with the present disclosure;

FIG. 5 illustrates an exemplary shipping box deployed for use on a store shelf, in accordance with the present disclosure;

FIG. 6 illustrates an alternate embodiment of an exemplary shipping box in an undeployed state, wherein the shipping box includes a high profile separation line in comparison to the shipping box of FIG. 5, in accordance with the present disclosure;

FIG. 7 pictorially illustrates an exemplary front side and an exemplary back side of a granular granola product provided in four sided pillow packages, in accordance with the present disclosure;

FIG. 8 pictorially illustrates an exemplary side view of a granular granola product provided in a four sided pillow package, in accordance with the present disclosure; and

FIG. 9 pictorially illustrates an exemplary shipping box in a deployed state and an undeployed state, in accordance with the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, wherein the showings are for the purpose of illustrating certain exemplary embodiments only and not for the purpose of limiting the same, FIG. 1 illustrates a front side of an exemplary four sided pillow package for use in providing a food product to the consuming public. Package 10 comprises two flat pieces of material initially sealed along three sides, side 12, side 14, and side 16. The materials of the flat pieces can be heat sealed, for example, creating a 5 mm seal, according to methods known in the art. However, in the preferred embodiment of the present invention the edges of the material are joined by ultrasonic welding. Package 10 is filled with product and some amount of air and is subsequently sealed along side 18 at seal 20. Tear features 50 a and 50 b are located at a location near the tops of edges 14 and 16, respectively. One tear feature can be provided. More than two tear features can be provided. A consumer can open package 10 by applying a shearing force at either feature 50 a or 50 b. The package is most likely to tear along line 51. Hole 52 is provided as an option for retailers to hang the product from a hook in a store.

Without limitation, the packaging can include any suitable dimensions not limited in one instance to a range of 1-4″ width. From a functionality standpoint, separate from marketing or artwork considerations, and in order to comfortably fit in a user's hand during one handed and tilted consumption, the selected width of the packaging can preferably be in the 1-4″ width range (such as 2.5″ in one non-limiting instance).

Additional considerations for sizing the width of the packaging in this range include accomplishing a clean tear across the packaging width, thereby making it easy for the product contained therein to be poured evenly. It is also desired that the tear line maintain a generally planar dimension relative to the bottom of the package, as a vertical tear often results in unintended spillage of the contents and of not pouring correctly or making a perfect circle when applying pressure on the sides (such as each being 5 mil in thickness in one non-limiting instance).

Marketing images are printed on the front side 11 of package 10. The marketing design of the illustrated package 10 is exemplary and not intended to be a limiting example of marketing that can be printed on a three sided pillow package. A primary product logo 32 is predominantly displayed at a top location upon package 10 such that it is the first thing that a consumer sees of the product. Images are illustrated stopping some distance from the edge of the packaging. However, in another embodiment, the images can go completely to the side edges of the packaging.

Logo 32 is contained within region 33 which is located below features 50 a and 50 b, such that line 51 is entirely above region 33 and the logo 32 contained therein. Other packaging methods that result in a flap running the length of the back side of the product frequently include serrated, stamp sealed edges at either end of the packaging. These serrated edges are normal to the center of the packaging and the marketing printed thereupon. These serrated edges provide an easy starting point for a consumer to open such packaging. However, such a tear line starting at one end of the packaging tends to propagate down the length of the packaging, frequently causing the tear line to go immediately through the primary marketing material of the packaging, thereby violating and destroying the marketing value of the packaging as soon as the packaging is open. Package 10, instead, by locating tear features away from marketing material on the front of the package and with resulting line 51 along which the packaging is most likely to open being above primary logo 32, the marketing value of the package remains intact even after the product is opened. Additionally, marketing and product description information 34, 37, 38, and 40 can be arranged. According to one embodiment, a color coded bar 36 can be posted on a central banner 30 to convey a particular flavor or variety of product to the consumer.

Packaging that includes a fold along the back side of the product is typically made of a foil or thin plastic material. Rolls of material are fed into a machine which mechanically wraps the product and ultrasonically seals the packaging along the fold and at each end. Manipulation of the product, wrapping the product, creating the fold, etc. are optimally accomplished with a very pliable packaging material. A four sided pillow package does not include the wrapping operation of the product, nor is the packaging required to make sharp bends as are required in forming the fold along the back side of the package. As a result, a wider variety of materials can be used to create a four sided pillow package. For example, a thicket gage plastic material can be used. Such a thicker gage enables the packaging to have visual effects not possible in super thin packaging, such as a semi-clear or translucent package permitting the consumer to see the product within the package. Package 10 includes exemplary regions 54 a and 54 b wherein, when a transparent or translucent material is utilized. Further, the thicker gage plastic can have a weightier feel for the consumer, conveying a more substantial product image to the customer than the thin packaging can convey.

Thick gage plastic sealed along four edges can apply a force upon the product contained within. Wherein thick gage plastic or other thick gage or rigid materials are utilized, a loose or granular product can be included in the packaging. Any force applied to a granular product by the packaging simply rearranges the product without damaging the product. Products formed into rigid bars, bars coated with chocolate, or other rigid products might be damaged or lose an original appearance if placed in a three sided pillow package constructed of a thick gage material.

A number of materials are envisioned for use in the disclosed packaging. According to one embodiment of a method to construct a polymer based wrapper, typical bag construction can be made using various plastic films laminated together using adhesives or coextruded using a molten polyethylene. The material must be food grade material. The material must be able to be sealed/joined along the edges of the packaging. The material must be able to accept marketing and other printing upon the outside surface of the packaging. One exemplary material that can be used for the packaging includes rice paper. According to one embodiment, a very thin layer of rice paper can be used between layers of plastic films, wherein the rice paper provides an appearance and texture to the packaging. At least one layer of plastic film can be used between the rice paper and the food product to maintain the water-proof properties of the packaging, avoiding any moisture from the product in reaching and discoloring the rice paper. In one embodiment of rice paper, the rice paper cannot act as a barrier, so at least one layer of barrier material must be used in combination with the rice paper. In one embodiment, the rice paper can be used as an outside layer of the packaging. In another embodiment, at least one layer of plastic film can used between the rice paper and the exterior surface of the packaging, for example, to facilitate effective printing upon the exterior of the packaging. In one embodiment, a layer of transparent or nearly transparent 12 micron polypropylene can be used as an external or outside layer for ease of printing on the packaging. In one embodiment printing is performed on the inside of the polypropylene layer, the polypropylene layer is laminated to the rice paper layer, and the ink of the printing is therefore protected between the two layers and is visible to the outside of the packaging through the polypropylene layer. According to one embodiment, the rice paper can include cut-out sections, for example, permitting transparent windows through a portion of the packaging where the rice paper is not present, while continuing to present the rice paper visual properties in the rest of the packaging. Such a cut-out section can be created by utilizing a custom die cut tool to create the rice paper in the appropriate dimensions.

FIG. 2 illustrates a back side of the four sided pillow package of FIG. 1. A four sided pillow package such as package 10 has a flat surface on rear side 100 with no fold running the length of the back of the package. As a result, marketing images 130 and 110 can be printed on the back of the package. In this way, a four sided pillow package more effectively presents marketing material to consumers by utilizing space on the back side of the packaging in addition to using the front side. Rear side 100 includes exemplary marketing image 130 including a gold colored flourish image 132 surrounding portrait image 134. Further, exemplary marketing image 110 presents a story about the product. Tear features 50 a and 50 b are located such that a consumer opening the package at the tear features is unlikely to tear through either image 130 or image 110, thereby leaving the marketing intact after the consumer opens the package. Image 120 is illustrated including exemplary required disclosures such as nutritional information, ingredients, and a bar code symbol. Seal 20 is additionally illustrated.

FIG. 3 illustrates a front side of an exemplary four sided pillow package, wherein a top of the package has been removed across a tear line defined by two tear features. Package 10 is illustrated including front side 11, region 33 including a primary logo, and tear features 50 a and 50 b. The package has been torn along line 51 creating edge 222 and resulting in a lower portion 210 of package 10 including the food product and an upper portion 220 including a remnant that can be thrown away. Edge 222 is illustrated between tear features 50 a and 50 b, wherein the edge 222 does not go through region 33, thereby permitting the marketing image within region 33 to remain intact.

FIG. 4 illustrates a back side of the four sided pillow package of FIG. 3. Package 10 is illustrated including back side 100, image 130, and tear features 50 a and 50 b. The package has been torn creating edge 222. Upper portion 220 is illustrated. Edge 222 is illustrated between tear features 50 a and 50 b, wherein the edge 222 does not go through marketing image 130, thereby permitting the image 130 to remain intact.

FIG. 5 illustrates an exemplary shipping box deployed for use on a store shelf. Box 250 is illustrated including a box front 260 and a box side 270. Box side 270 includes a marketing logo 272. Exemplary box 250 is initially shipped as a complete box with six rectangular sides, wherein a top of the box can be torn off along exemplary perforations, creating a container that can be used as an in-store display. Box 250 with the top torn off includes edges 280 a, 280 b, 280 c, and 280 d. Box 250 is configured to be just wide enough for packages 10 a, 10 b, 10 c, and 10 d to fit within the box, thereby making the packages easy to remain aligned while on display.

FIG. 6 illustrates an alternate embodiment of an exemplary shipping box in an undeployed state, wherein the shipping box includes a high profile separation line in comparison to the shipping box of FIG. 5. Box 300 is illustrated including box bottom 310 and box top 320. Perforated line 330 c is illustrated as part of perforations around box 300 such that box top 320 can be torn off and box bottom 310 can be used as an in-store display. A high profile box bottom can be defined by line 330 c. An alternative low profile box can be defined if the perforations are cut along a lower line (edge 280 c shown for comparison). A high profile box can be utilized when it is preferred that the packages be retained within the box more effectively. A low profile box can be utilized when it is preferred that the product be more visible to consumers. A box with perforations matching both a high profile box and a low profile box can be utilized, permitting the store to decide which profile to utilize.

FIG. 7 pictorially illustrates an exemplary front side and an exemplary back side of a granular granola product provided in four sided pillow packages. Front side 11 is illustrated, including a color banner 36 identifying a particular flavor. Rear side 100 is illustrated including marketing image 130. Seal 20 is illustrated. Although seal 20 is provided along a bottom of the package, the seal can be located at the top or along one of the sides of the product.

FIG. 8 pictorially illustrates an exemplary side view of a granular granola product provided in a four sided pillow package. Front side 11, edge 14, clear region 54 a, and rear side 100 are illustrated.

FIG. 9 pictorially illustrates an exemplary shipping box in a deployed state and an un-deployed state.

Such other features can additionally include a four sided ultra-sonic sealing of any suitable composition or thickness of film layers formed into a four sided package, such further utilizing an associated ultrasonic film machine which can be incorporated into an assembly line and process for creating a pillow packaging as described herein. Such an assembly and process can, without limitation, include an assembly for producing a four sided pillow package (such as exhibiting a total thickness of 4 mils) and which includes the provision of a pair of roller fed plastic sheet stock along with a vertically supported forming template about which opposing lengths of the sheet stock are positioned, at which point initial heat sealing of the top and sides is accomplished.

The manufacturing process then causes the package to be reoriented with the open bottom facing upwardly, following which your proprietary funnel design fills the three enclosed side defining interior with a volume of loose fill material (e.g. granola, powder, liquids, etc.). The remaining fourth side (open bottom) is then heat sealed closed to complete the assembly and to create a free standing packaging which allows for single handed emptying of in-filled contents without the incidence of collapse of the packaging material.

As previously described, the packaging and related assembly and forming processes is not limited to loose fill materials such as granola, and can be configured to package and retain the freshness of a variety of different edible and non-edible goods not limited to liquids, other solids, etc. The disclosure has described certain preferred embodiments and modifications of those embodiments.

Additional features associated with the manufacturing process and assembly for ultrasonic forming the package, in-filling the material and sealing can include each of the following enumerated steps:

Positioning the flexible material (pouch material) on a roll with the (non-print or printed) impressions on left and right side of the flexible material;

Winding the flexible material into the machine;

Forming the flexible material into a pouch or whatever type of packaging that is required for the application;

Ultrasonically sealing the pouch on the left, right and bottom of the pouch with ultrasonic sealing jaws;

Moving the pouch into position for filling with the product by the use of either volumetric or weight process;

Once the pouch is filled, ultrasonically sealing it along the top with the fourth and final seal;

Transferring the completed pouch through a metal detector on the single row conveyor and then go through inkjet for Mfg code, etc.

Further modifications and alterations may occur to others upon reading and understanding the specification. Therefore, it is intended that the disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims. 

I claim:
 1. A package for use in providing a food product to a consumer, the device comprising: a four sided pillow package of ultrasonically sealable material.
 2. A package for use in providing a food product to a consumer, the device comprising: a four sided pillow package, wherein the package includes a gold colored flourish image surrounding a portrait image.
 3. A package for use in providing a food product to a consumer, the device comprising: a four sided pillow package, wherein the package comprises a marketing image and two tear features, such that if the package is torn between the two tear features the marketing image is not torn.
 4. The package of claim 1, wherein the package is formed by ultrasonic welding of the material. 